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DOE OSTI2020

Characterization and Scaling of Forced Convective Swirl in Sinusoidal Wavy-Plate-Fin Cores of Compact Heat Exchangers

The characterization and scaling of the thermal-hydraulic performance in wavy plate-fin compact heat exchanger cores, based on the understanding of the physical phenomena and heat transfer enhancement mechanism is delineated. Experimental data are presented for forced convection in air (Pr = 0.71) with flow rates in the range 50 ≤ Re ≤ 4000. A variety of wavy-fin cores that span viable applications, with geometrical attributes described by the cross section aspect ratio α (ratio of fin spacing to height), fin corrugation aspect ratio γ (ratio of 2× corrugation amplitude to wave pitch), and fin spacing ratio ζ (ratio of fin spacing to wave pitch), are considered. To characterize and correlate the vortex-flow mixing in interfin spaces, a Swirl number Sw is introduced from the balance of viscous, inertial and centrifugal forces. It is shown that the laminar, transitional and turbulent flow regimes can be explicitly identified by this Swirl number. Based on the experimental results and extended analysis, new correlations for Fanning friction factor f and Colburn factor j are developed with Sw, α, γ, and ζ as scaling parameters. Requisite expressions are devised by a superposition of both enhancement components due to the corrugated surface area enlargement and induced swirl flow field, and they are combined to cover the laminar, transitional and turbulent regimes by the method of asymptotic matching. The resulting generalized correlations are further shown to predict all available experimental data for f and j factors to within ±20% and ±15%, respectively.

42 ENGINEERING↗

DOE OSTI2020

Experimental evaluation of the role of redox during glauconite-CO 2 -brine interactions

Greensands formations are globally abundant sedimentary rocks rich in Fe clays (typically glauconite) that commonly contain natural hydrocarbon accumulations and may be important reservoirs for geologic storage of anthropogenic CO 2 . Diagenesis in greensands is commonly accompanied by the conversion of primary glauconite to siderite (FeCO 3 ), a process that could be exploited for the permanent trapping of CO 2 . Importantly, siderite formation after glauconite requires that the mostly oxidized Fe in the primary Fe clay minerals is reduced during diagenetic interactions. Here, we explore the effect of solution redox state on the stability of glauconite in sandstones with implications for the diagenetic and/or engineered formation of siderite. We performed two flow-through experiments on intact, glauconite-rich sandstone cores at 150 °C and 150 bar. Both experiments employed a 1 mol NaCl/kg, 0.1 mol NaHCO 3 /kg solution charged with ~0.58 mol CO 2 /kg solution, but the redox state of the injected fluid was manipulated between experiments in order to compare glauconite reactivity and siderite saturation state at oxidizing and reducing end-member conditions. After reaction with the oxidizing (O 2 (aq) ≈ 6 μmol/kg) fluid, chemical and Mӧssbauer spectroscopic analyses indicate the production of Fe(III)-oxy/hydroxide minerals from glauconite, whereas, in the reducing (H 2 (aq) ≈ 5–40 mmol/kg) experiment, thermodynamic calculations and coupled chemical, mineralogical, and Mӧssbauer analyses suggest glauconite dissolution and precipitation of an Fe(II) mineral, likely siderite, and minor magnetite formation. These experimental results, along with thermodynamic calculations, confirm that solution redox state is the master variable dictating siderite formation in greensands.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2021

CFD analysis of a solid pin-fueled small modular fluoride salt-cooled reactor

A computational fluid dynamics (CFD) study is performed for the pre-conceptual solid pin-fueled small modular fluoride salt-cooled reactor developed by the Oak Ridge National Laboratory (ORNL). The solid and fluid regions in a 1/12th section of a fuel assembly are modeled. The solid region includes fuel and non-fuel pins, with heat generation in the active region of the fuel pins. Two different power profiles, uniform and center-peaked, are considered. The FLiBe coolant flows from the bottom to the top of the core, parallel to the bank of fuel and non-fuel pins. The k-ω shear-stress transport (SST) model is chosen as the baseline turbulence model. The effects of grid refinement, inlet turbulence specification, and turbulence models on the temperature and pressure drop predictions are studied. Turbulence model sensitivity is investigated by comparing the results from the k-ω SST model with other two-equation models (k-ω baseline or BSL and k-ε realizable) as well as with anisotropic Reynolds stress transport models (linear pressure-strain and stress-BSL). Here the results show that the choice of turbulence model has a significant impact on the pin temperature and bundle pressure drop predictions. The results from the baseline turbulence model show good agreement between the fuel pin temperatures and bundle pressure drop values predicted using a subchannel model previously developed by the authors of the present study.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2022

Shock wave formation from head-on collision of two subsonic vortex rings

Vortex ring collisions have attracted intense interest in both water and air studies (Baird in Proc R Soc Lond Ser Math Phys Sci 409:59–65, 1987, Poudel et al. in Phys Fluids 33:096105, 2021, Lim and Nickels in Nature 357:225, 1992, New et al. in Exp Fluids 57:109, 2016, Suzuki et al. in Geophys Res Lett 34, 2007, Yan et al. in J Fluids Eng 140:054502, 2018, New et al. in J Fluid Mech 899, 2020, Cheng et al. in Phys Fluids 31:067107, 2019, Hernández and Reyes in 29:103604, 2017, Mishra et al. in Phys Rev Fluids, 2021, Zednikova et al. in Chem Eng Technol 42:843–850, 2019, Kwon et al. in Nature 600:64–69, 2021). These toroidal structures spin around a central axis and travel in the original direction of impulse while spinning around the core until inertial forces become predominant causing the vortex flow to spontaneously decay to turbulence (Vortex Rings, https://projects.iq.harvard.edu/smrlab/vortex-rings). Previous studies have shown the collision of subsonic vortex rings resulting in reconnected vortex rings, but the production of a shock wave from the collision has not been demonstrated visibly (Lim and Nickels in Nature 357:225, 1992, Cheng et al. in Phys Fluids 31:067107, 2019). Here we present the formation of a shock wave due to the collision of explosively formed subsonic vortex rings. As the vortex rings travel at Mach 0.66 toward the collision point, they begin to trap high pressure air between them. Upon collision, high pressure air was imploded and released radially away from the axis of the collision, generating a visible shock wave traveling through and away from the colliding vortices at Mach 1.22. Our results demonstrate a pressure gradient with high pressure release creating a shock wave. We anticipate our study to be a starting point for more explosively formed vortex collisions. For example, explosives with different velocities of detonation could be tested to produce vortex rings of varying velocities.

42 ENGINEERING↗

DOE OSTI2021

Thermal confinement and transport in spherical tokamaks: a review

Here, we review the thermal plasma confinement and transport properties observed and predicted in low aspect ratio tokamaks, or spherical tokamaks (STs), which can depart significantly from those observed at higher aspect ratio. In particular, thermal energy confinement scalings show a strong, near linear dependence of energy confinement time on toroidal magnetic field, while the dependence on plasma current is more modest, the opposite of what is seen at higher aspect ratio. STs have revealed a very strong improvement in normalized confinement with decreasing collisionality, much stronger than at higher aspect ratio, which bodes well for an ST-based fusion pilot plant should this trend continue at an even lower collisionality than has already been accessed. These differences arise because of fundamental differences in transport in STs due to the more extreme toroidicity (i.e. reduced region of bad curvature), and to the relatively larger $E_r \times B$ shearing rates, both of which can suppress electrostatic drift wave instabilities at both ion and electron gyroradius scales. In addition, electromagnetic effects are much stronger in STs because they operate at high β T . Gyrokinetic (GK) studies, coupled with low- and high-k turbulence measurements, have shed light on the underlying physics controlling transport. At lower β T , both ion- and electron-scale electrostatic drift turbulence may be responsible for transport. At higher β T , microtearing, kinetic ballooning, and hybrid trapped electron/kinetic ballooning modes increasingly play a role, and they have a much stronger impact in the core of ST plasmas than at higher aspect ratio. Flow shear affects the balance between ion- and electron-scale modes. Non-linear GK simulations find regimes where the electron heat flux decreases with decreasing collisionality, consistent with the experimental global normalized confinement scaling. The ST is unique in that the relatively low toroidal magnetic field allows for localized measurements of electron-scale turbulence, and this coupled with turbulence measurements at ion-scales has facilitated detailed comparisons with GK simulations. These data have provided compelling evidence for the presence of ion temperature gradient and electron temperature gradient turbulence in some plasmas, and direct experimental support for the impact of experimental actuators like rotation shear, density gradient and magnetic shear on turbulence and transport.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2026

Applications of Solid-State Transformers for Electric Power Grid HEMP/GMD Resilience

A high-altitude electromagnetic pulse (HEMP) or geomagnetic disturbance (GMD) can disrupt power grids by inducing low-frequency common-mode (CM) currents. When these currents flow through grounded transformers, they can bias the magnetic core, driving it into saturation and reducing performance or damaging equipment. This work presents a solid-state transformer (SST) to replace vulnerable assets and improve grid resilience. The paper reviews half-cycle saturation in conventional transformers, then describes an SST architecture that neutralizes and redirects CM currents during HEMP/GMD events. A prototype SST is built and validated, demonstrating stable CM-disturbance operation and protection of nearby transformers. Finally, large-scale simulations show how coordinated SST deployment mitigates CM disturbances and strengthens overall grid resilience.

four-leg inverter↗

DOE OSTI2020

Potential Formation Damage: An Integrated Reservoir Characterization Study of the Naturally Fractured Carbonate Middle Duperow Formation at the Kevin Dome, Montana

In this study, we integrate geologic and engineering data of a naturally fractured carbonate reservoir at the Kevin Dome, Montana. Well test data are correlated with core description, geochemical and lithology study to determine the flow behavior and communication within the injection test interval and to the surrounding area. Based on a dual-continuum geologic model, numerical brine injection simulations are carried out to validate the interpretation results from our well test analytical models and forecast the probability of CO 2 injection success using current reservoir properties. As a result, our well test analytical models as well as lithology/core description suggest that fluid flow may be mainly restricted to the injection interval and the assumption of radial (horizontal) flow may be appropriate. The well test models also indicate that there is potentially formation damage with a positive skin factor although prior to brine injection well tests, well stimulation through acid treatment was performed. Our numerical simulation results appear to confirm this formation damage by showing additional pressure buildup in the injection data during later test periods. To explain this, acid may have dissolved dolomite then dolomite or calcite may have been formed again further into the matrix/fracture system. Another possible explanation is mechanical clogging of the fractures due to acid dissolving dolomite and dislodging fine grains. Our work also predicts that if no additional well stimulation is performed, the project will have a lower probability of successfully injecting 1 million tons of CO 2 into the Middle Duperow formation over 4 years.

42 ENGINEERING↗

DOE OSTI2021

Ducted Assembly Steady-State Heat Transfer Software (DASSH): Theory Manual

The Ducted Assembly Steady-State Heat transfer software (DASSH) is being developed at Argonne National Laboratory to obtain a steady-state thermal fluids result for the coolant flow and temperature distribution in a hexagonally gridded reactor core with ducted assemblies. In DASSH, each assembly is assumed to contain a hexagonal bundle of wire-wrapped pins. DASSH divides the coolant in the pin bundle into subchannels on which it applies energy balances to determine coolant and duct temperatures. DASSH offers multiple models for inter assembly heat transfer and features the ability to calculate pin temperatures. This document describes the models and equations implemented in DASSH. It includes a description of the geometric system to which the models are applied and a derivation of the subchannel energy balance formulation is presented. It also reviews the available correlations and provides an overview of the process by which power distributions are generated. Finally, it covers the code execution procedure, discussing the main code objects and their interactions.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2023

Fiscal Year 2023 Software Quality Assurance Activities for the ARC Software

The Argonne Reactor Code (ARC) software suite [1-17] has been developed by Argonne researchers for fast reactor design and analysis since the 1970s. With the ARC software suite, a user can quickly build a model of a proposed or existing fast spectrum reactor and carry out fuel cycle, nominal thermal analysis and flow requirements, and assess, as is appropriate, whether the core design and constraint system yield an acceptable mechanical behavior. For transient reactor analysis with SAS4A [18], the ARC software suite can be used to generate reactivity coefficients and kinetics parameters at any modeled fuel cycle time point which forms part of the input to SAS4A. The ARC suite was consistently being developed until the 1990s and followed a software QA program which was an appropriate standard for the time. In the 1990s, the DOE funding to fast reactor research and development was all but eliminated and the ARC software was put into maintenance mode. In the early 2000s, the software quality assurance (SQA) program for ARC was still in place to define an official version, but by 2005 it all but was abandoned as there were insufficient staff to fill the work roles. Since 2005, there has been a considerable increase in research and design work on fast spectrum reactors. The ARC software as a whole has since been exported to many universities and commercial companies and ANL support has been given to the various projects over the years [19-23]. Further, MC 2 -3, PERSENT, and DASSH were all developed after 2005 without any adherence to a software standard. In recent time, the DOE VTR project [22] paid for verification work to be done on the ARC software as part of the goal of making it NQA-1 complaint. The VTR project was not considered the appropriate pathway to fund and maintain a SQA program for the ARC software and while software developments (DASSH) were made and several manuals were updated and software verification work was carried out, the ARC software is not NQA-1 compliant. More recently the Advanced Reactor Development Program (ARDP [23]) has funded the creation of manuals for some ARC utility programs and funded additional software verification work on DIF3D [6, 7] and MC 2 -3 [2-5] for the purpose of commercial grade dedication. Because of the VTR and ARDP projects, software verification work was completed on MC 2 -3 and DIF3D, and detailed reports were created for each piece of software, which discuss the inputs and outputs from the codes that are covered by the verification work and link various analytic, code-to-code, and hand calculation based verification work presented in the report with verification test problems provided with the software. This is a key part of the commercial grade dedication work and constitutes the bulk of the cost to get the ARC software to commercial grade. The ARC software suite is a valuable asset as a fast reactor design and analysis tool set that has been reasonably well verified and validated with various fast reactor benchmark problems and experiments over decades. Some or all of the ARC software suite has been utilized for designing the IFR [20], PGSFR [21], VTR [22], and Natrium [23] reactors and we can expect it to continue to be used for advanced fast reactor design and/or confirmatory calculation purposes in the future. Due to increased interest by commercial companies and regulatory bodies, it is becoming more important to make the ARC software suite complete and ready-to-use in terms of its SQA pedigree and commercial grade dedication needs. This report discusses the achievements made towards building a new SQA program for the ARC software and dealing with outstanding identified QA gaps.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2024

Code Benchmark of Depressurized Conduction Cooldown Transient in the High Temperature Test Facility

This paper presents results from modeling of a depressurized conduction cooldown (DCC) transient at the High Temperature Test Facility (HTTF) as part of the OECD-NEA Thermal Hydraulics Code Validation Benchmark for High-Temperature Gas-Cooled Reactors using HTTF Data . This paper briefly describes the benchmark and the models being used. It then presents a comparison of steady state and transient results based on the Problem 2 Exercise 1A and 1B definitions. We compare block and helium temperature distributions, mass flow distribution, and energy balance in steady state. All models show comparable mass flow distributions and energy balances. The temperatures within the core and outer regions are comparable in all models too, but inner reflector temperatures can vary significantly. Despite that, we find that the models are in good agreement for the full-power steady state. In the DCC, we look at block temperature at the core midplane and RCCS water exit temperature. The INL and ANL models are found to be in excellent agreement with one another on block temperature over time, while the agreement when the KAERI and NRG models are added into consideration is good. Differences in the transient heat removal from the RCCS cause the differences in block temperature over time in these models. The CNL models show similar trends to the INL, ANL, KAERI, and NRG models, but the temperatures are high because the volumes used in calculating the average temperature include the heater rods in the CNL models only. The HUN-REN model shows results that suggest significantly lower heat removal in the RCCS which merit further investigation.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2022

Modelling the Alfvén eigenmode induced fast-ion flow measured by an imaging neutral particle analyzer

An imaging neutral particle analyzer (INPA) provides energy and radially resolved measurements of the confined fast-ion population ranging from the high-field side to the edge on the midplane of the DIII-D tokamak. In recent experiments, it was used to diagnose fast-ion flow in the INPA-interrogated phase-space driven by multiple, marginally unstable Alfvén eigenmodes (AEs). Here, the key features of this measured fast-ion flow are: (I) a fast-ion flow from q min and the injection energy (81 keV) towards lower energies and plasma periphery.(II) A flow from the same location towards higher energies and the plasma core, (III) a phase-space 'hole' at the injected energy and plasma core and (IV) a pile-up at the plasma core at lower energies (~60 keV). Ad hoc energetic particle diffusivity modelling of TRANSP significantly deviates from the observation. Comparably, a reduced modelling, i.e. a combination of NOVA-K and ASCOT5 code with the measured mode structure and amplitude, generally reproduce some key features of the observed phase-space flow, but largely failed to interpret fast ion depletion near the plasma axis. At last, self-consistent, first-principle multi-phase hybrid simulations that include realistic neutral beam injection and collisions are able to reproduce most features of the time-resolved phase-space flow. During consecutive hybrid phases, an RSAE consistent with the experiment grows and saturates, redistributing the injected fast ions. The resulting synthetic INPA images are in good agreement with the measurement near the injection energy. The simulations track the fast-ion redistribution within the INPA range, confirming that the measured fast-ion flow follows streamlines defined by the intersection of phase-space surfaces of constant magnetic moment μ and constant E' = nE + ωP φ , where n and ω are the instability toroidal mode number and frequency, and E and P φ the ion energy and toroidal canonical momentum. Nonperturbative effects are required to reproduce the depletion of fast ions near the magnetic axis at the injection energy.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2023

Core Model Proposal #: 374 Global Iron and Steel Trade

This core model proposal (CMP) enables GCAM to track the gross trade of regional iron and steel commodities. Following the logit-based Armington trade modeling framework, this CMP aims to improve the representation of physical output (Mt) flows in GCAM v6.0’s iron and steel sector. In addition, the core model proposal also updates the regional steel demand and improves the representation of iron and steel technologies (and their energy coefficients) across all GCAM regions.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2025

HFIR LEU High Density Silicide Dispersion Optimized Design Steady-State Heat Transfer Analyses

Steady-state heat transfer simulations of the Oak Ridge National Laboratory High Flux Isotope Reactor (HFIR) with the low-enriched uranium (LEU) high-density silicide dispersion Optimized fuel design were performed to support comprehensive performance and safety metric studies concerning this design. The LEU Optimized design operates at 95 MW to maintain HFIR’s current highly enriched uranium (HEU) core performance level at 85 MW. Full cycle Mode 1 full flow Case 1 (inlet temperature), Case 2 (flux-to-flow), and Case 3 (inlet pressure) safety limit analyses were performed to assess the margins to critical heat flux. Under the prescribed conditions, this LEU design meets the safety limit and limiting control setting requirements outlined in HFIR’s documented safety analysis; however, the safety margins are less than those for the 85 MW HEU core, and several assumptions were made where fuel fabrication and qualification data are currently lacking for the silicide fuel design. Effects of changes to pertinent fuel fabrication assumptions and uncertainty factors on thermal safety margins were also evaluated, showing that the margins are sensitive to many of these parameters. Power and pressure perturbations were also performed, indicating that significant steady-state thermal margins could be gained by increasing the coolant inlet pressure.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2021

PELICAN Design, Test Planning, and Commissioning Results

To support design efforts for the Versatile Test Reactor (VTR) core assemblies, an experimental facility has been designed and constructed at Argonne National Laboratory to match the hydraulic flow conditions within the VTR’s primary heat transport system (PHTS). This facility, the Pressure drop Experimental Loop for Investigations of Core Assemblies in advanced Nuclear reactors, PELICAN, provides the ability to measure pressure drop across a full-scale fuel assembly containing prototypic axial reflectors, fuel, and plena components. The PELICAN facility was designed and built to offer maximum flexibility, allowing testing from short sub-sections all the way to the full-length core fuel assemblies. The report presents the high-level program objectives, a summary of the facility design, instrumentation, and control systems, and the testing procedure. The outcomes from facility characterization efforts and first test matrix results are then presented and then, finally, the conclusion contains a summary of the future work to be performed. This test facility was designed to match the hydraulic conditions of the flowing sodium in the VTR using water as a surrogate fluid. To do so, the water is elevated to a temperature of 110°C where its viscosity matches that of sodium, and with a 50-HP centrifugal pump, is capable of generating full scale flow rates to achieve prototypic Reynolds and Euler number flow conditions. To prevent boiling, the system is maintained at elevated pressure of at least 2.7-3.0 bar (40-44 psig). A set of 15 tests have been used to perform checkout activities in order to commission the device, survey the capabilities of PELICAN, and generate experimental data at isothermal conditions and over a range of flow rates up to 44 kg/s (700 GPM) to produce datasets used in the verification and validation of VTR design and modeling efforts. Initial testing focused on facility characterization, which assessed the operational capabilities of various control systems. The thermal control system was qualified, including the thermal response of the loop to the heat added by self- and auxiliary heaters, the chiller and heat exchanger systems for removing excess heat, and their coupled ability to maintain steady-state isothermal conditions as desired. Additionally, the pressure control system was verified to ensure necessary operating environments that promote pump health and prevent boiling of loop inventory at high temperatures could be met. With these systems in place, the first set of matrix tests have been carried out using orifice plates with inner diameters of 2.25-inches and 2.5-inches. Orifice plate flow behavior is well covered in scientific literature, and the results find good agreement with the measured pressure drop vs flow rate and those of theoretical predictions. This initial testing not only helps to validate the experiment, but it also produces a high quality data set for a geometry that is easily reproducible for simulations. Finally, the report is concluded with a discussion of the work to come and provides a snapshot of the test articles in the experimental pipeline whose designs are being inspired by the current designs from the VTR.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2023

Multiphysics Simulations of MSRE with NEAMS Thermal Hydraulics Tools

This report documents the benchmarks being developed and simulations performed using tools and codes developed under the Nuclear Energy Advanced Modeling and Simulation (NEAMS) program, utilizing MSRE experimental data. In FY23, three main work scopes were investigated under the NEAMS MSR work package at ANL. The first scope investigated the Griffin-SAM coupling model for simulating the pump startup transient experiment of MSRE. The analyses start with a simple model (single-channel, single-lattice), gradually adding more details (multi-channel, full-core) into the model. The results show that the reactivity loss curve is very sensitive to the axial boundary conditions and the radial core discretization. The simple model can predict a similar reactivity trend as that of the more sophisticated model, which is likely due to error cancellation. Accurately modeling the axial boundary condition may further improve the reactivity trend but would require significant efforts to generate the mesh of the MSRE inlet and upper plenum. The core channel radial discretization for the Griffin-SAM coupled model also depends on the flow distribution. Given the complex geometry in the inlet plenum, the flow distribution needed to be calculated from CFD analysis, which was performed using the NekRS code. This analysis employed a MSRE CAD model developed by Copenhagen Atomics. The CAD model was disassembled to keep the inlet plenum region only, which was subsequently cleaned and modified so that the mesh generated is under the memory limit. The results are merged to a few radial regions to show that the flow rate is highest in the central region. This would be useful for future improvement of the Griffin-SAM coupling model of the MSRE core. The last task investigated is tritium transport modeling using the standalone SAM code. This task aimed to initiate the effort to demonstrate and validate the tritium transport model implemented in SAM. The preliminary investigation employed an MSRE model consisting of the primary loop. Three tritium transport pathways were examined including the retention in the graphite, the permeation through the HX tube wall, and the removal from the off-gas system. The results compare well with the MSRE data, but improvements are still needed on the initial conditions (i.e., the present state may not have reached equilibrium), the boundary conditions, the off-gas system modeling, and a better numerical strategy to reach the equilibrium state.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2023

Effects of drifts on scrape-off layer transport in W7-X

Abstract Drifts affect particle, momentum, and energy transport in the scrape-off layer (SOL) of tokamaks and stellarators, altering plasma flows and creating asymmetries between divertors. To understand how drifts affect SOL transport in the W7-X island divertor, an experiment was performed to compare plasmas with matched core parameters but opposite magnetic field directions, and therefore opposite drift transport directions. Parallel flow measurements made with coherence imaging spectroscopy are interpreted with the aid of a diagnostic forward model and a 1D simple SOL model that includes the E × B drift. In low-density plasmas ( n ‾ e < 2 × 10 19 m −3 ), the poloidal E × B drift induces a large poloidal density asymmetry within the island SOL, as measured by divertor Langmuir probes. This in turn causes the parallel flow stagnation point to shift from the position halfway between targets to the X-point in the drift direction, leading to near-unidirectional flow throughout the SOL. As density increases, the effects of the poloidal E × B drift decrease substantially, resulting in a smaller density asymmetry and the development of a counter-streaming flow pattern. For the entire density range probed in this experiment ( n ‾ e = 1.5 − 6 × 10 19 m −3 ), the experimental observations are more consistent with the effects of the poloidal E × B drift than the radial E × B drift.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2026

Structural uniformity and compositional homogeneity of solid-phase alloyed rod

Solid-phase processes have emerged as an alternative to fusion-based alloying to avoid coarse microstructures, undesirable phase formation, and high energy consumption. However, achieving uniform distribution of alloying elements during friction-based processing remains challenging due to highly heterogeneous thermomechanical conditions. This work evaluates the structural uniformity and compositional homogeneity of Al–Cu–Zn alloyed rods produced by friction extrusion (FE) and establishes the role of the rotational speed to feed rate ratio (N/V) on alloying effectiveness. A systematic matrix of FE experiments was conducted at constant extrusion ratio with N/V values ranging from 3.7 to 300. Compositional uniformity was assessed along the rod length (ICP-OES), in three dimensions (X-ray computed tomography), and at the microscale (SEM–EDS), supported by a gray-level co-occurrence matrix (GLCM)–based homogeneity metric. Smoothed particle hydrodynamics (SPH) simulations were used to reveal material flow and thermomechanical fields. Results show that N/V = 100 produces a high-shear mixing zone that eliminates the unmixed core and enables near-full dissolution and dispersion of Cu and Zn. At lower N/V, a laminar flow region persists at the rod center, causing segregation and large composition gradients. The combined experimental–computational analysis provides mechanistic insight into the transition from fragmented particle dispersion to thermomechanically assisted metallurgical mixing. This study establishes processing–structure relationships for solid-phase alloying and provides guidance for achieving homogenized compositions comparable to wrought alloys via rapid, scalable FE processing.

Aluminum↗

DOE OSTI2024

Demonstration of a multi-channel fluidized bed particle–supercritical carbon dioxide heat exchanger for concentrating solar applications

High-temperature thermal energy storage in oxide particles at temperatures above 600°C can couple concentrated solar energy with high-efficiency thermal power cycles to provide dispatchable solar-driven electricity. Challenges remain in developing cost-effective primary heat exchangers, which require expensive alloys, to extract the high-temperature thermal energy from the particles to power cycle fluids, such as supercritical CO 2 (sCO 2 ) in recuperated Brayton cycles. To explore one pathway for cost-effective, high-temperature particle heat exchangers, the current study demonstrates a shell-and-plate, particle–sCO 2 heat exchanger with narrow- channel fluidized beds coupled with micro-channel sCO 2 flows in the heat exchanger walls. This study evaluates the feasibility of multiple parallel, narrow-channel fluidized beds in shell-and-plate particle–sCO 2 HXs, to achieve high bed-wall heat fluxes at elevated temperatures. A reduced-order model simulates the narrow- channel, fluidized-bed particle–sCO 2 heat exchanger to design the fluidized bed geometry, in terms of depth, height, and number of channels,for a nominal 40-kWth heat exchanger at particle and sCO 2 inlet temperatures up to 600 °C and 400 °C respectively. The resulting shell-and-plate heat exchanger design operates with bubbling fluidization of the downward-flowing oxide particles to enhance bed-wall heat transfer. The heat exchanger core is fabricated with etched sCO 2 micro-channels in thin wall plates that are diffusion bonded to spacer frames to form the shell-and-plate structure with 12 parallel, fluidized bed channels, 10.4 mm deep. The heat exchanger is tested at the National Solar Thermal Test Facility at Sandia National Laboratories with CARBOBEAD HSP particles at design particle flow rates of 0.20 kg s –1 and inlet temperatures up to 525 °C. Results show that fluidization across multiple parallel channel beds can maintain uniform particle inventory with a common freeboard zone above the heat exchanger core. Bubbling fluidization improves particle–wall heat transfer coefficients but also increases axial dispersion of particle thermal energy, which lowers the log- mean temperature difference such that total heat transfer remains relatively constant to within ±10% over a broad range of fluidization gas velocities. The axial dispersion required particle and sCO 2 flow rates to be increased by 25% over model-designed conditions to achieve the targeted 40 kWth, which indicates the importance of incorporating axial dispersion into heat exchanger design models and of deploying bed structures to suppress it. Furthermore, this study demonstrates the feasibility and preferred fluidizing gas conditions for particle heat exchangers for releasing high-temperature thermal energy storage systems.

14 SOLAR ENERGY↗